SURFACE ROUGHNESS AND MACHINING FORCES WHEN APPLYING MINERAL AND VEGETAL BASED CUTTING FLUIDS IN END MILLING OF ABNT 1045 STEEL

MATHEUS MARTINS CARRARA¹; EDER SILVA COSTA¹; WISLEY FALCO SALES¹; ÁLISSON ROCHA MACHADO¹

¹ Faculty of Mechanical Engineering

doi:10.20906/CPS/COB-2015-1866

Resumo

In end milling process the cutting edge is either in the tangential face as the front face, moreover, the relationship between the diameter and the length of the cutter is large, causing high overhanging of the tool. These factors characterize the low stiffness of these processes, making the chip removal rate small, and causing damages in the surface quality and the cutting forces. To obtain better tolerances and surface finish certain factors must be considered, including the stiffness of the tool, the cutting parameters, the machining forces and cutting fluid. For this reason, the cutting fluids are of fundamental importance in tool wear and quality of the machined surface. Due to high operational costs and legal requirements related to the environment and to human health, researchers have tried to minimize the use of cutting fluids or even eliminate them completely (dry machining). For this reason, among the conciliatory alternatives the use of a less aggressive fluid to the operator and environment and techniques for reducing the amount of fluid, especially the application MQL (Minimum Quantity of Lubricant) are included. This work studies the machining forces and the surface finishing when using different lubri-cooling systems of vegetable and mineral basis. The surface finish was quantified by Ra and Rz parameters and the machining force by the Fx component and torque. HSS-Co end milling cutters, with two sharp edges, coated with TiAlN and uncoated, with 10 mm diameter were used in machining of ABNT 1045 steel plates. In addition to the coating were varied the axial depth of cut, the feed rate, the cutting speed and the lubri-cooling system [dry machining, MQL, Low volume (dripping) and flood cooling]. Analysis of the results obtained through a Factorial Design of Experiments (DOE) with five factors at two levels suggests that the performances of the vegetal and mineral base cutting fluids were similar.

Palavras-chave: End milling; Cutting fluids; ABNT 1045 steel; Surface roughness; Machining forces and torque